I was changing the belt that Dave snapped while tuning the 120" 2000 FatBoy and while putting the starter jackshaft back on I set my 1/4" torque wrench to 110 in-lbs as specified but the jackshaft rod snapped. Seems like I am cursed these days, the Buell has a fried ECM as well, haha!
Now I have to remove the oil tank to remove the starter to get the snapped off piece out of there (this is gonna be fun).
I was reading the procedure for removing the oil tank and they have all those fancy tools for disconnecting the oil lines from the tank. I was wondering if they are really needed or is there a way around it.

On my 2008 softail I just pull the bottom hose off that leads to the engine (feed hose) and pop out the return and the breather lines then you can swing the oil tank out of the way while its still attached to the other hose (drain hose) that is way underneath. This is the reason I am going to go to a chain drive because it is way too big of a pain to change a belt. Anyway, Im guessing yours would be nearly the same but not totally sure. Hope it helps.

Just looked at my manual and you don't need those silly little tools fore removing the lines, just squeeze the clips together and pop them out theres a few orings in there so just make sure you either get them out or they are not blocking the way when you go to push them back in.

no tools needed, pull back the chrome covers and use small pick tools to disenguage the plastic clips and work the lines out. they suck. almsot as much as pulling the bag out. take your time bro, it'll all work out. prolly could have done a chain convert for what the belt cost.

loctite on the threads? did it go in difficult? if it went in easy and you just overtightened, it might come right out. if not, you can get service parts for your starter. and then there's always drilling....

loctite on the threads? did it go in difficult? if it went in easy and you just overtightened, it might come right out. if not, you can get service parts for your starter. and then there's always drilling....

No loctite on the threads. It didn't go in difficult, I was tightening it and it just started spinning "too easily" then broke off. I won't be able to get a replacement part unless I contact Custom Valley because if I remember well, there is a jackshaft extension that goes with the 240 wide tire kit. I might try a left hand drill bit and try to spin it out.

Yves, do you have to pull the starter out? With the primary off there should be some room to work, maybe not enough though.I feel your pain though, just did a starter on a softail last week......I checked on their site, looks like they have a longer coupler and bolt than stock.

Yves, do you have to pull the starter out? With the primary off there should be some room to work, maybe not enough though.I feel your pain though, just did a starter on a softail last week......I checked on their site, looks like they have a longer coupler and bolt than stock.

Sorry for the run of bad luck...

Hi Dan, I think I won't have a choice, I have to go dig for that bit that snapped off, plus it looks like I'll have to order the bolt from Custom Valley because it appears like it is longer due to the offset caused by the 240 tire kit.
....and the throttle cable on the FatBoy started to fray.... and the internal throttle is seizing up.... I think I'll retire the FatBoy for the rest of the summer, haha!

I don't know for sure but I pulled the tank once to remove the starter, but looking at things it would seem easier to pull the battery cables off of the starter after the battery is out and yank the primary with starter attached. Then again I'm getting really fast at yanking the primary components. Anybody done it this way before? The tank route is such a pain in the ass, which I did during the HQ build.
Ron

I don't know for sure but I pulled the tank once to remove the starter, but looking at things it would seem easier to pull the battery cables off of the starter after the battery is out and yank the primary with starter attached. Then again I'm getting really fast at yanking the primary components. Anybody done it this way before? The tank route is such a pain in the ass, which I did during the HQ build.
Ron

You mean pull the starter from the left side of the bike?
There is a piece of the engine case in the way on that side (believe me, I thought about that too). So unless you can squeeze the starter through that little hole, you can't do it, haha!

I just pulled a starter myself to get the inner primary off my 01 Fatboy. Those oil lines friggin suck. Go to the dealer and get the two replacement gizmo things that have new quick connects and new o-rings with alignment tool. Only a few bucks each. Pull the old o-rings and spacers out of the tank prior to replacing the new ones obviouisly. My originals were hard as a rock and couldnt get the lines back in worth a crap. So new stuff was put in. Then a little assembly lube (ie. Lubriplate) and eased em back in as I was swinging the tank into place. Just my two cents......oh yeah.....economy bad.....just my ONE cent.....hahaha.....

I just pulled a starter myself to get the inner primary off my 01 Fatboy. Those oil lines friggin suck. Go to the dealer and get the two replacement gizmo things that have new quick connects and new o-rings with alignment tool. Only a few bucks each. Pull the old o-rings and spacers out of the tank prior to replacing the new ones obviouisly. My originals were hard as a rock and couldnt get the lines back in worth a crap. So new stuff was put in. Then a little assembly lube (ie. Lubriplate) and eased em back in as I was swinging the tank into place. Just my two cents......oh yeah.....economy bad.....just my ONE cent.....hahaha.....

Thanks for the advice, I'll be putting the oil tank back tomorrow after work, I'll see how it goes and may order those parts if need be (unfortunately for me, the closest dealership is 6hrs away).

OHHHHH!! Six hours.....that sucks. Well, be aware of them things and go easy with plenty of slippery goo and it all should be well. Mine got pulled sideways a little on the disassembly, so check em man....later

I was changing the belt that Dave snapped while tuning the 120" 2000 FatBoy and while putting the starter jackshaft back on I set my 1/4" torque wrench to 110 in-lbs as specified but the jackshaft rod snapped. Seems like I am cursed these days, the Buell has a fried ECM as well, haha!
Now I have to remove the oil tank to remove the starter to get the snapped off piece out of there (this is gonna be fun).
I was reading the procedure for removing the oil tank and they have all those fancy tools for disconnecting the oil lines from the tank. I was wondering if they are really needed or is there a way around it.

Thanks in advance for any help.

done it a few times without removing the oil bag
I had to pull the rear tire and remove the plastic lower fender and go through the opening after unscrewing the plastic cover on the fender to get one screw and used 3 extensions (used 3 instead of one long one to have a little flex) and went between the oil bag and the tranny from the other side to get the other bolt out.
you could use a flexable extension. but it was far easyer than pulling the bag

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